Making Snacks in a More Sustainable Way

The next time you bite into a Frito-Lay snack, consider this – that crunchy, tasty snack might just have come from one of our sustainability-minded manufacturing facilities in the U.S.

Just over 10 years ago, our Casa Grande, Arizona facility was transformed into a sustainability “learning lab” where we challenged ourselves to think differently about renewable energy sources, water technologies and the amount of waste we were sending to landfills. We knew if we could test, optimize and scale practical solutions at Casa Grande we could implement these changes at plants across the country.

As you can imagine, this was and is quite an undertaking as this facility is responsible for producing millions of bags of snacks every year, which include fan favorites like Lay's and Ruffles potato chips, Doritos and Tostitos tortilla chips, Crunchy and Baked Cheetos cheese snacks, Fritos corn chips and SunChips multigrain snacks, just to name a few.

Our resource conservation teams led the way in helping us successfully identify numerous resource- and cost-saving solutions helping take our facility “off the grid” as much as possible.
Renewable Energy: 
To address renewable energy sources, we installed a 60,000 pound-per-hour biomass boiler, which uses wood and agriculture waste as an energy source to produce steam required to power our manufacturing plant. Using innovative technologies like this continues to reduce Casa Grande’s reliance on the electric grid, generating more than 50 percent of site-wide energy from biomass and solar sources.
Water Efficiencies: 
Our water-recovery system is designed to capture, treat and filter waste-process water so the water can be reused in production. Casa Grande’s manufacturing lines currently use 75 percent recycled process water, enabling Frito-Lay to reduce its annual water use by 100 million gallons – this amount of water can fit into 150 Olympic-size swimming pools, dramatically cutting our use of this precious resource.

Reducing Waste:
We then looked at waste, we determined we could launch a program to recycle and reuse food waste, sending it offsite for cattle feed. This allowed us to cut the amount of waste we send to landfills to less than one percent helping us achieve nearly zero waste to landfill.

As you can see, Frito-Lay is committed to meeting its sustainability goals. These efforts to be more sustainable in our practices have been recognized by national, state and local organizations across the country. And we’re not stopping here. We’re also looking for new and innovative technologies we can test and potentially deploy for further reductions.


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